mubea specification - part 1 · a1 – control cabinet – location designation +01 o functional...

ZBF-FA-6-002

Mubea Specification - Part 1

-

Equipment guidelines for the creation

of electro-technical systems

Creator: Pohlmann, Gerrit

Version: July 2018

The functional specification and additional documents are available in the cur-

rent version on the Mubea net in the category

"Central units / Central unit production technologies / automation"

as well as, for external companies, in

http://www.mubea.com/mubea-info/pflichtenheft/ .

http://www.mubea.com/mubea-info/pflichtenheft/

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MUB-GES-GES-ELO-GER-01 Mär14

I Table of contents

Content

I Table of contents ........................................................................................ 2

1 Contact persons and information ............................................................. 4

2 General regulations .................................................................................... 5

3 Documentation and data storage .............................................................. 6

3.1 Documentation ..................................................................................... 6

3.2 Documentation languages .................................................................... 7

3.3 Electronic data storage......................................................................... 7

4 Circuit diagram creation ............................................................................ 9

4.1 Circuit diagram designation .................................................................. 9

4.2 Project planning ................................................................................. 10

4.3 Setup of the project hierarchy ............................................................ 10

4.4 Labelling of terminal strips .................................................................. 11

4.5 Operating supplies labelling ............................................................... 12

4.6 Symbol creation ................................................................................. 12

4.7 Potential designations ........................................................................ 13

4.8 Bus systems documentation (particularly profibus) ............................ 13

5 Operating voltages Mubea plants ........................................................... 14

6 Control cabinet technology (without PLC) ............................................. 15

6.1 Control cabinets ................................................................................. 15

6.2 Air conditioning ................................................................................... 15

6.3 Other control cabinet components ..................................................... 16

7 Control (PLC) and operator units (HMI) .................................................. 17

7.1 Touch panel and control panels ......................................................... 17

7.2 Controls and industrial PCs ................................................................ 18

7.3 Preferred types of control terminals Beckhoff ..................................... 18

7.4 Switches and other displays (command/signalling devices) ............... 19

7.5 Access control (EKS) ......................................................................... 19

8 Sensory analysis ...................................................................................... 20

8.1 Temperature measurement technology.............................................. 20

8.2 Safety sensors ................................................................................... 21

8.3 General sensory analysis ................................................................... 21

9 Actuator engineering ................................................................................ 22

9.1 Pneumatics ........................................................................................ 22

9.2 Hydraulics .......................................................................................... 23

9.3 Electrical drives .................................................................................. 23

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10 Robots ....................................................................................................... 24

11 Cabling ...................................................................................................... 25

11.1 Cable/core colours and cross sections ............................................... 25

11.2 Cables, ducts, terminals ..................................................................... 25

11.3 Plug connectors (energy, communication) ......................................... 26

11.4 Sensor/actuator distribution device .................................................... 26

12 Bus systems and network ....................................................................... 27

12.1 Profibus .............................................................................................. 27

12.2 General installation instructions: ........................................................ 27

12.3 Measuring points for NW analysis ...................................................... 28

12.4 Quality proof (acceptance and examination) ...................................... 28

12.5 Ethernet network ................................................................................ 28

12.6 General network configuration ........................................................... 28

12.7 AS interface (ASi fieldbus) ................................................................ 29

12.8 Laying specifications .......................................................................... 29

12.9 Quality proof (acceptance and examination) ...................................... 29

12.10Ebus (energy data measurement) ..................................................... 30

13 Software and programming ..................................................................... 31

13.1 PLC programming .............................................................................. 31

13.2 HMI design and programming ............................................................ 34

13.3 Symbols used ..................................................................................... 34

13.4 User interface design ......................................................................... 35

13.5 Machine Data Acquisition (operating and process data) .................... 36

14 Capture of energy data ............................................................................. 39

14.1 Procurement specification for measuring devices .............................. 39

14.2 Measurement of electric power .......................................................... 39

14.3 Measurement of other media ............................................................. 41

14.4 Gases / compressed air ..................................................................... 42

14.5 Measurement of water........................................................................ 43

15 Miscellaneous ........................................................................................... 44

15.1 Linking of systems .............................................................................. 44

16 Lists of preferred parts and preferred configurations ........................... 45

17 Appendix ................................................................................................... 46

17.1 Linked documents and links ............................................................... 46

17.2 Figures ............................................................................................... 46

4


1 Contact persons and information

Contact persons for control technology at Mubea locations worldwide

Location/area Name Telephone E-mail

Contact person Functional specification / Attendorn

G. Pohlmann +49 2722 62 9798 [email protected]

[email protected]

Weißensee M. Buttgereit +49 36374/23-1280 [email protected]

Daa-den/Weitefeld

A. Schadener +49 2743 806312 [email protected]

H. Schumann +49 2743 806310 [email protected]

Prostejov / Czech Republic

Jindrich Lakomy (AF)

+420 582 778 480 [email protected]

Peter Hampl (SF)

+420 582 778 480 [email protected]

Florence / USA B. Hebenstiel +1 859 746 5300 ext. 7523

[email protected]

Zebrak / Czech Republic

Miroslav Skoula +420 311907 286 Miroslav.Skoula@ mubea.com

Taubate / Brazil

Mauro Cesar +55 12 3627 5017 [email protected]

Saltillo / Mexico

Melfi / Italy Giovanni Di

Nunno

[email protected]

Taicang / China Ranxiang Pan +8613913791366 [email protected]

Bedano Luca Bongiani +41919357917 [email protected]

mailto:[email protected]:[email protected]

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2 General regulations

Systems and control cabinets are designed according to DIN EN 61439 and EN

60204 (VDE 0113, Part 1).

The Machinery Directive 2006/42/EC must be observed.

The supplier is obligated to design the system to meet the appropriate German and

European legislation, especially according to the Technical Working Materials act

– in the respective valid version - according to Art. 100a of the EU Contract.

With systems intended the for USA it must be ensured that all components are UL

certified. Wiring and components must be labeled according to EN/DIN/VDE though

(no AWG wiring and without core designation).

The CE label must be attached inside on the control cabinet door.

The manufacturer's information, power rating and circuit diagram number must be

attached on a sign inside on the control cabinet door.

The system must be checked according to DGUV-3 and the test report must be

included with the documentation.

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3 Documentation and data storage

3.1 Documentation

The documentation must be prepared according to the valid CE/DIN/VDE standards

and has to include the following documentation parts:

General

o Operating instructions / rating plate copy

o Declaration of conformity

o Manufacturer's declaration of the sub suppliers

o Documentation of hazard analysis and risk assessment

o System description (general operation, emergency-stop area, distribution

and operation of the functional groups, basic settings, HMI job profiles, pro-

gram structure)

o Description of the monitoring facility

o Description of the applied and purchased components

o Instruction for care and maintenance

o Full parts list with specification of the manufacturer

o Data sheet with system parameter

o Calculated nominal current and nominal power

Electronics

o System configuration with all components used

o Description of purchased parts like PC, PLC, drive controller etc.

o Two copies of the circuit diagram, DIN A4 as well as on a data medium (Am-

peresoft ProPlan or PDF format)

Documentation for the bus and Ethernet cabling

Documentation of the AS-I bus cabling with type and address information

of participants

o Printout of the AS-i monitor protocol (incl. version no.) (see Figure 17-1)

o Test report in accordance with DGUV-3 (see Table 17-1: Prüfproto-

koll_DGUV-3_xxx_Datum.pdf)

Fluid (in coordination with Mubea)

Software

o Delivery of one set of PLC source code (in German, English or local lan-

guage)

o Delivery of one set of HMI source code

o Delivery of all required GSD files (see chapter 13)

o Delivery of all program libraries (see chapter 13)

o Delivery of the ASi monitor project

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o Delivery of all additional project plans (drive controller, etc.)

Documentation texts are to be drawn up with MS-Word with one copy in English and,

if necessary, on in the respective local language (English, Italian, Czech, Spanish etc.).

3.2 Documentation languages

German English Local language Comment

Circuit diagram o x

User interface (HMI) o x

PLC program o o

Machine labelling x Use symbols!

Operating instructions x

CE / Declaration of conformity x

Installation instructions de-vices

o o

rating plate x

x: Mandatory

o: Optional

3.3 Electronic data storage

The control project or the machine software must be filed Figure 3-1on the Mubea

system server (x-Laufwerk\ATT\ZBF_ELO\Projekte) according to the folder structure.

All libraries and GSD files as well as other system software must be stored together

with the project.

Access data to the system server (x drive) can be obtained in the control technology

department or filed for the respective location in: x:\ATT\CUPT_AUTOMATION\. Pro-

jects of suppliers must be stored by a Mubea employee or can be sent to the above

address.

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Figure 3-1: Predefined folder structure for machines and systems

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4 Circuit diagram creation

The chapter "Circuit diagram creation" is an excerpt from the "Circuit diagram creation

manual" (internal Mubea use only).

4.1 Circuit diagram designation

The circuit diagram designation is assigned as follows:

[abbr. supplier] [year] [month] [abbr. area] [serial no.]

[abbr. supplier] : see Table 4-1

[year] : year (two-digit)

[month] : month (two-digit)

[abbr. area] : see Table 4-1

[serial no.] : unique serial number (two-digit)

Expl.: MA1203AF01

The enclosed table shows usable abbreviations for suppliers and product areas.

(Please request new abbreviations from [email protected]):

Table 4-1: Abbreviations for suppliers and product areas

Supplier Product area

Abbrevia-tion Meaning

Ab-bre-via-tion Meaning Translation (Engl.)

M, MA Mubea Attendorn AF Axle springs Axle springs

MZ Mubea Zebrak FBS spring band clamps Spring band clamps

MU Mubea USA NW camshaft Camshaft

MT Mubea Taicang SF Stabilisers Stabilisers

AT Atesi TF Tellerfedern Disc springs

ES Eswo-Tech VF Ventilfedern Valve springs

MW Weitefeld TRB Tailor rolled blanks Tailor rolled blanks

TRT Tailor rolled tubes Tailor rolled tubes

RW Getriebewellen Gear shafts

TZ Technologiezentrum (Prüf- und Messmaschinen)

Technology centre (testing machines and measuring ma-chines)

KSB Kopfstützbügel Headrest supports

RSP Riemenspanner Belt tensioner

SUS Stanzen und Schweißen Punching and welding

CT Carbon Teile Carbon parts

GTF Getriebetellerfedern Gear disc springs

TMC Transmission components Transmission components

AL General/Others General/others

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4.2 Project planning

Circuit diagrams are to be created with the software ProPlan of the company Am-

peresoft.

A sample project is available on the Mubea network under tool making / control

technology.

Circuit diagrams contain parts lists of all components

4.3 Setup of the project hierarchy

Load and control part of a drive must be drawn in one functional group.

Each side of the schematic circuit diagram should have 10 current paths.

Components that are not in a control cabinet, control panel or terminal box must

get the location designation +ext = external.

The following project structure is to preferably be provided for during project planning:

A1 – Control cabinet – Location designation +01

o Functional groups

000 General overviews – e.g. cover sheet, project overview

001 Machine views – e.g. machine overview

002 General views – e.g. control cabinet view

010 Power supply – e.g. supply line, PSUs, potentials

015 Lighting, air conditioning

020 Emergency stop

025 Safety – e.g. safety doors, two-handed actuation

100 PC

105 – 195 Drives

200 PLC overview

250 Field devices overview

300 Bus systems overview

360 Bus topology overview

500 Terminal plans

A2 – Control panel – Location designation +02

o Functional groups






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020 Emergency stop


100 PC

105 – 195 Drives

200 PLC overview




500 Terminal plans

A3 – External terminal boxes Location designation +03……e.g.+09

o Functional groups






020 Emergency stop


100 PC

105 – 195 Drives

200 PLC overview




500 Terminal plans

A100 - Equipment overviews

004 Lists of individual items

005 Wire lists

4.4 Labelling of terminal strips

Terminal strips are labeled according to the following system:

[functional group]X[type].[ser. no.]

[functional group] : see chapter 4.3

[type] : see table

[unique serial. no.] : unique serial number (two-digit)

Expl.: 110X1.2 (2nd clamp main current of the functional drive group 110)

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Table 4-2: Abbreviations for terminal strip types

Terminal strip type Terminal strip type

Abbreviation Type Abbreviation Type

General: Bus systems:

X0 Supply line X30 SUCOnet K

X1 Main current X31 ASi

X2 Emergency stop X32 ASi Safety

X3 Panel / control positions X33 Profibus DP

X10 Control voltage 230V AC X34 CAN

24V DC: Special types:

X20 24C DC supply X40 Measurement lines

X21 Digital inputs X50 Potential-free

X22 Digital outputs

4.5 Operating supplies labelling

Operating supplies are labeled according to the following system:

[functional group]-[sheet functional group][identification letter][current path]

[functional group] : see chapter 4.3

[sheet functional group] : no. of the sheet in the circuit diagram

[identification letter] : identification letter according to IEC Standard 60617-2

[current path] : no. of the current path of the operating supplies

Expl.: 110-1B6

4.6 Symbol creation

Symbols should be created according to IEC standard 60617-2.

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4.7 Potential designations

Designation Potential Description

L01 230V AC Control voltage before emergency stop

L02 230V AC Control voltage after emergency stop

L00 230V AC neutral

L011 24V DC Supply voltage assemblies, PLC etc.

L012 24V DC Supply voltage sensors, buttons, indicator lights

L013 24V DC Supply voltage actuators after emergency stop

L015 24V DC Supply voltage actuators after emergency stop and protective

device

4.8 Bus systems documentation (particularly profibus)

All participants must be displayed with the true physically installed sequence as bus-

topology in the schematic circuit diagram, preferably on one sheet.

(see example: Profibus-Docu.pdf according to Table 17-1 no. 3)

The following information must be included:

Slave addresses

Mounting position of participants

Participant type

Information on the line lengths laid between the respective participants and speci-

fication of the total length per segment

Bus segments must be clearly visible

The termination (bus end) must be indicated with an icon

Measuring points that are intended or were used for quality determination of the

network must be apparent.

"Coming" and "Going" must be indicated with arrows ("IN"/"OUT") on the icons

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5 Operating voltages Mubea plants

Europe /

China USA Brazil

Saltillo, Mexico

(*1)

Celaya, Mexico India Japan

Operating voltage 3Ph

3x400V +10%, 50Hz

3x480V + 5%, 60Hz

3x380 V, 60Hz

3x460V + 5%, 60Hz

3x400V, 60Hz

3x400V +10%, 50Hz

3x420V 50 Hz

Operating voltage 1Ph/N

230V, 50Hz

115V, 60Hz

230 V, 60 Hz

115V, 60Hz

115V, 60Hz

230V, 50Hz

230 V 50 Hz

Valve voltage 24V DC 24V DC 24V DC 24V DC 24V DC 24V DC 24V DC

Brake voltage 24V DC 24V DC 24V DC 24V DC 24V DC 24V DC 24V DC

Sensor actuator supply

24V DC 24V DC 24V DC 24V DC 24V DC 24V DC 24V DC

An additional 400V-coil must be provided for U.S. matching transformers.

To avoid vagrant currents, a 5-conductor network must be used (separate N and

PE conductor!)

(*1): Mexico axle spring hall: 400V, 60 Hz

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6 Control cabinet technology (without PLC)

6.1 Control cabinets

Device setup and wiring on galvanized mounting plate with cable ducts, considering

EMC Directive 2004/108/EC (Directive relating to electromagnetic compatibility)

Installation reserve in control cabinet for the extension of fuses, covers, terminals

and motor protection switches on the busbar: min. 20%

Busbar support by Eaton: List of preferred parts

During the installation of lighting and 220V socket

o these must be connected to the main switch for repairs.

o a fault current circuit breaker (rated residual current 30mA) must be used.

Alternatively, elcb/mcb combination switches can also be used.

o these must be realized with LED lamps.

If possible, do not install operating elements and components in the side walls

Adjustable operating elements (e.g. thermostats) must be secured with a lockable

disc

Cable supply from the bottom, sealing with divided base plate with foam rubber

A circuit diagram tray must be provided for in the control part on the inside of the

door.

The contact bar for the neutral conductor (N) must be protected against accidentally

contact with a (transparent) cover.

Preferred groups for control cabinets see Appendix: List of preferred parts

Mubea_Pflichtenheft_Teil_2_Elektronische_Vorzugsteile

6.2 Air conditioning

The air conditioning must always be selected after consulting the person responsible

for the location because some plants operate central cooling systems.

All power switching stations that are not positioned in an air-conditioned switch

room must be equipped with an air conditioning unit. All remaining power switching

stations must be equipped with a door fan.

A heat requirement calculation for the design of the switching air conditioning must

be verified in writing (VDE 0660 Part 507). The following values must be assumed

for the heat calculation: Internal temperature: 35°C, ambient temperature: 40°C or

50°C with placement in a not air-conditioned switch cabinet platform.

The air conditioning units must be switched with a door contact.

16


A condensate drain must be installed.

A signal contact must be read into the PLC.

An integrated control cabinet inside temperature display with a PT100 sensor must

be provided.

With air conditioning units that cool several control cabinets (no partition or side

wall between the control cabinets), the door contact switches of these control cab-

inets must be connected in series so that the opening of any control cabinet door

switched off the air conditioning unit. Furthermore, an interior control cabinet fan

must be installed for better heat distribution.

When using air-water exchanger, it must be ensured that the water flow tempera-

ture in small plants is not above 25°C.

Preferred types for air conditioning units see Appendix:

Mubea_Pflichtenheft_Teil_2_Preferred_electronic_components

6.3 Other control cabinet components

Preferred types for switching devices and additional control cabinet components

see Appendix:


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ZBF-FA-6-002

7 Control (PLC) and operator units (HMI)

7.1 Touch panel and control panels

Masks are designed with the visualization software "Galileo" version 8.0 or higher (Mi-

cro Innovation) (HMI-design see chapter 13).

Preferred types for touch panel and control panels see Appendix:


Figure 7-1: Touch panel Beckhoff CP7932-1184

When using a touch panel, the following functions must be

carried out via an additional mechanical button:

Automatic start (white illuminated pushbutton)

Automatic stop (black push button)

Material feed on (WS black)

Control voltage on (white illuminated pushbutton)

Control voltage off (black push button)

Emergency-off button with protective collar

Operating mode selector switch type T0 with SVA (key switch with 3 setting in

the sequence: 0 - Manual - Auto)

Acknowledgment protective device (blue push button)

Enabling button (by Euchner in side wall)

18


The AS-i bus system is used for the control panels as standard bus systems. For ena-

bling button, manual selector switch, auto selector switch and emergency stop, secure

AS-i circuit boards (AC015s) by IFM must be used. For automatic start/stop, control

voltage on/off, material feed on and acknowledgment protective device, active AS-i

modules (AC2752) by IFM must be used!

If no display is used, indicator lights for

General fault (red)

Basic setting (yellow)

Protective device

must also be provided. They can be displayed as an icon in the appropriate mask on

the display. (See Mask design)

On programming port (Ethernet connection RJ45) must be provided on the control

panel.

7.2 Controls and industrial PCs

Standard controls are the embedded PCs CX5130, CX2020 (poss. CX20xx) as well as

industrial PCs of the series CP69xx.

Preferred controls types, see Appendix: :


Standard industrial PC configuration, see Appendix: CP6920


Observe the latest IT security guidelines when commissioning industrial PCs and con-

trollers (separation of production networks by VLANs, antivirus management, Windows

updates). See also "One-Pager - Industrial IT Security (DE).pdf".

Further installation notes - see document "Beckhoff IPC - Initial Ersteinrichtung.docx".

Document installation steps with important access data in the checklist: "Checklist

Beckhoff IPC Initial Ersteinrichtung.docx" and save it in the project folder.

The UN/PW combination must be saved to the Elo system server Access data must

also be stored on the Elo plant server in the Excel overview file of the machines (IP

addresses of Maschinensteuerungens.xls).

7.3 Preferred types of control terminals Beckhoff

Non-local bus terminals are connected via

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ZBF-FA-6-002

Ethercat bus (EK 1100)

Ethernet (BK9000) (Ethernet network configuration see Ethernet)

Profibus (BK3120) (profibus network configuration see profibus configuration)

The field level is connected via ASi bus (see chapter 12.7)

or via Ethercat

K bus terminals are no longer to be used.

For digital I/O terminals, preferably terminals with 8 channels should be used.

All Beckhoff terminals can be used. For a selection see:


7.4 Switches and other displays (command/signalling devices)

Preferred types for switches and displays see:


Figure 7-2: Switches of the series RM Titan (Eaton), clear text display EZ-Automation (right)

7.5 Access control (EKS)

Use the key data of the program "EKS Master X" for editing. Logging is done

automatically on the server. Drivers, operating instructions and detailed infor-

mation are in the program folder.

The different levels can be used to manage access to overall systems and par-

tial machines.

Each user level automatically receives all authorizations of the corresponding

subordinate user level (hierarchical structure).

Table 7-1: Operator level and groups based on key colour

Level (4..49) Colour Group

4..9 green Operators

10..19 yellow Fitters

20..29 black Skilled workers (toolmakers), persons in charge of

quality control

30..39 blue Electronics engineers

40..49 red Programmers

Preferred types for access systems see:


20


8 Sensory analysis

8.1 Temperature measurement technology

The characteristics of temperature measurement sensor technology with application

range are listed as follows:

Contact-based temperature measurement

Thermocouples

Fast measurement

Large temperature range

High temperatures

Metal resistance thermometer (positive temperature coefficient thermistor /

PTC)

High accuracy

Slow measurement

Temperature range up to 850°C

Contact-free temperature measurement

o Pyrometers

o Fast measurement

o Large temperature ranges

o Pyrometers should be able to display the measurement point po-

sition e.g. via laser.

o Emissivity must be established

o Does generally nor require external evaluation software

o Thermal imaging cameras

o Fast measurement

o Large temperature ranges

o Pixel by pixel temperature output / analysis of individual areas

possible

o Requires evaluation software

o Requires trained personnel

o Enables quantity and quality analysis

o Emissivity must be established

Preferred types for temperature measurement see:


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8.2 Safety sensors

Preferred types for safety sensors and safety systems of the door switch see:


For robots, the use of an additional safety controller as an alternative to light cur-

tains must be examined.

8.3 General sensory analysis

Use only 3-line initiators with connector plug and optical display on the end-switch

side.

Displacement path transducers must be connected with an SSI interface.

Preferred types for sensors see:


22


9 Actuator engineering

9.1 Pneumatics

A solenoid valve with which the system is depressurised with switched off control

voltage must be installed before every maintenance unit.

When selecting the valves, it must be made sure that the pressure drop does not

cause dangerous movements of machine components when the control voltage is

switched off. This may also apply to the switching on.

A pressure monitor switch must be provided.

Specified hose colours are: Working stroke – blue, return stroke – black

The pressure should be reduced to a minimum (e.g. 6.0 to 6.5 bar). If individual

systems require a higher operating pressure, then this must be realized as an iso-

lated application with separate compressors or booster pumps, if necessary.

If the control voltage is turned off, the system is to be depressurized if possible

(stop valve).

Preferred types for pneumatics see:


Sample maintenance unit configuration see: Maintenance unit MSB6:


Figure 9-1: Left: MSB4-1/4:C4:J1:F6-WP; right: MSB6-1/2:C4:J1:V4-WPB

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ZBF-FA-6-002

9.2 Hydraulics

Hydraulic aggregates must be equipped with electrical fill level query and filter con-

trol.

Pressureless circulation must be installed with a motor performance of 7.,5KW or

higher.

A servo motor must be provided as drive with 7.5 kW or more. System pressure

must be recorded with a pressure transducer (opt. 4-20mA) and regulated to an

adjustable value in the user interface (PI or PID).

Temperature sensing with PT100

Equip pressure reservoir with quick discharge

Manual cut-off valve

Operation must preferably be provided demand-controlled via frequency inverter.

Preferred types for hydraulics see:


9.3 Electrical drives

Three-phase motors with 7.5 KW and higher must start in star-delta.

Three-phase motors with load start-up must be equipped with heavy starting.

Three-phase motors between 0.75 and 375 KW must comply at least with EU effi-

ciency class IE3 (EU Regulation 640/2009).

Preferred types for motor drive technology see:


24


10 Robots

Robots are

4-5-6-axle: Motoman MH series preferred types MH180, MH50II, MH24

SCARA: Motoman YS series

All robots must be equipped with the Mubea specification provided to Motoman.

Pneumatic collision protection: IPR or Schunk

Tool changing systems: IPR or Schunk

Valve terminal see chapter 9.1

Sensor distributor (see list of preferred parts Phoenix Contact SACB-6/3-L-M16-

M8)

Protective hose for cable package type Murrplastik PAE

Protective clothing RCC, France

The robots are controlled via Ethercat.

The robot’s options are:

Safety control (recommended, when the robot can drive over the protective fence

area)

Conveyor function

Servo float (Mubea standard)

The stability of the robots must be ensured with sufficiently strong bases and ade-

quately dimensioned mounting with anchors/base screws or similar. In case of

doubt, the stability must be verified constructively.

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11 Cabling

11.1 Cable/core colours and cross sections

The following defaults must be adhered to:

Type Colour

Main current phase L1, L2, L3 black

neutral light blue

PE yellow-green

Control voltage phase red

Control voltage neutral red-white

Sensor-actuator supply + blue

Sensor-actuator supply - blue-white

Valve voltage + blue

Valve voltage - blue-white

Potential-free orange

Emergency stop control circuit purple

Sensors / controlling circuits white

Min. cross section for main power lines 1.5 mm2

Min. cross section for control power lines 0.75 mm2

Ethernet patch cables grey

Ethernet cross cables red

Ethercat bus cable (inside control cabinet) green

Profibus bus cable purple

Profibus bus cable purple

11.2 Cables, ducts, terminals

EN 50174-2 (installation of communication cabling) must be used as a basis for the

for the cabling of a system.

Correct earthing and potential equalization must be observed!

Cables shall be laid in sturdy ducts or cable drag chains (only drag-chain suitable

cables with tension relief)

Cable ducts must generally be covered and walkable areas must be supplied with

additional, non-slip mechanical protection.

Information technology cables and power supply lines must be laid in separate ca-

ble ducts. Outside the cable ducts, these lines must be laid with a distance of at

least 50 mm.

Preferred types for cables, ducts and terminals see:


26


11.3 Plug connectors (energy, communication)

Preferred types for plug connectors see:


11.4 Sensor/actuator distribution device

Preferred types for distribution devices see:


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12 Bus systems and network

The standard bus systems are Ethercat and ASi, as well as Ethernet. So far as neces-

sary, the profibus must be used to link external foreign modules.

12.1 Profibus

Preferred types for profibus hardware see:


12.2 General installation instructions:

All guidelines and recommendations of the PNO for standardized installation of the

profibus network must be observed (see installation guidelines profibus DP/FMS

according to Table 17-1 no. 1).

Only drag chain suitable profibus cables (AWG24/19) must be used

Compliance with line lengths depending on the baud rate.

Preferably use a baud rate of 1.5 Mbit/sec. Other baud rates only after consultation.

Correct connection of the data line (green=A; red=B)

During connection of the slaves with plugs or also with direct terminal connection,

the direction "coming" (direction from the PLC/CNC) and "going" (in the direction of

the next participant) must be observed. Connect the incoming line with 1A/1B (also

at the start of the bus) and the outgoing line with 2A/2B.

At the entry into the control cabinets or terminal boxes, the cable shield must be

applied extensively and low-ohmic via shield clamp.

With a new connection, the line end must also be new.

Sufficient reserve in the cable ducts at the connection point must be ensured ac-

cordingly.

Observe the bending radii of the lines (at least 10 x outer diameter!)

Terminal resistances must be placed on both ends of every profibus segment.

If several profibus DB slaves are arranged right next to each other (e.g. several

FUs in the control cabinet), then a profibus cable length of at least 1 metres must

be provided after every 3rd slave.

The bus addresses must preferably be assigned in ascending order (starting from

the master). Gaps in the addresses are permitted.

The master receives address 2, the 1. slave receives address 4

Passive stubs for the connection of slaves or also for measuring and diagnostics

purposes are generally prohibited! If the use of stubs cannot be avoided then these

must be active.

The following devices are to be used for this:

o Repeater or bus terminal

o Active programming cable

28


Different profibus cable type within one segment must be avoided because of the

reflections that are to be expected.

A maximum of 29 participants per bus segment is permitted for new systems. This

provides a reserve for possible expansion.

12.3 Measuring points for NW analysis

For inspection and repeat measurements as well as troubleshooting, nonreactive

measuring points for BUS analysis during operation must be provided at the start

and end of each segment.

Realisation can be done with a profibus plug with PG or also as a separate meas-

uring point in the form of active bus termination.

These measuring points must be designed to be accessible and clearly identified

in the topology plan.

12.4 Quality proof (acceptance and examination)

The supplier must verify the quality of the standardized installation and stable function

of the installed profibus network with measurements. The measurements must be

made on the fully installed system at the final installation site. The measuring and test

reports are part of the electrical documentation and must be submitted during machine

acceptance. (See example profibus measurement according to Table 17-1 no. 2).

The documentation must include:

Documentation of average / minimum / maximum bus cycle times

Check of error telegrams

In case the machine/system supplier is not in a position to carry out and document the

appropriate measurements, then a professional company must be commissioned.

12.5 Ethernet network

12.6 General network configuration

With more than 1 network participant, one sub-distributor must be provided per

machine.

o Unmanaged network switch with up to 8 participants

o Managed network switch with more than 8 participants

There should be at least 2 free ports available on every network switch (1 port for

the connection with the hall switch / intranet and 1 port for local connection of a

programming device).

Machine cabling should be on cross points (outlets) in the control cabinet with a

CAT5 cable of the type 2x2xAWG22 and SF/UTP conductor design.

The maximum line length of 100 metres must be observed.

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The outlets in the control cabinet are connected with the network switch with

shielded patch cables of the cat. CAT5 or higher.

RJ45 connectors CAT5 or higher with tool-free contacting must be used exclusively

(no crimp contacts!).

IP-address, subnet mask and gateway must be adjustable on every network par-

ticipant. (The data must be obtained from the system operator upon request.)

The network topology incl. IP addresses must be documented in the circuit dia-

gram.

Preferred types for Ethernet network see:


12.7 AS interface (ASi fieldbus)

Preferred types for ASi bus material see:


12.8 Laying specifications

The yellow profiled AS interface cable should be used. An alternative is a twisted

2-core 2 x 1.5 mm2 line (brown core for ASI+, blue core for ASi -).

The black profiled ASi line is used for the auxiliary power supply.

The max. segment length (incl. all stub cables) of 100 meters must be observed.

ASi cable laid separately from energy-carrying cables.

The ground/PE/shield connection of the ASi mains adapter must be connected with

the system ground for balancing.

12.9 Quality proof (acceptance and examination)

The supplier must verify the quality of the standardized installation and stable func-

tion of the installed ASi network through measurements. The measurements must

be made on the fully installed system at the final installation site.

The analysis should be made with at least 100,000 telegrams. The permissible er-

ror rate must be below 0.1 %.

The measuring and test reports are part of the electrical documentation and must

be submitted during machine acceptance.

For fast troubleshooting, status and diagnostic bits should be evaluated in the PLC.

The safety programming of ASi monitors must be included with the CE documen-

tation.

30


12.10 Ebus (energy data measurement)

The configuration of the E bus for energy data measurement is described in chapter

14.2.

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13 Software and programming

13.1 PLC programming

The host name of a control is assigned as follows:

[device][supplier][drawing number]

[type] : PLC

[device] : CX, PC, …

[circuit diagram no.] : Circuit diagram number

Example: PLCCXMA1203SF2

The AMS net ID is formed with the IP address (see chapter 12.6) amended with

digit group "1.1".

The control project / machine software must be saved to open the Mubea system

server according to chapter 3.3.

The designations of the program components should the preceded by the type:

Main program MP_....

Program component PC_....

Functional component FC_....

Action AC_....

An INFO file must be created in each PLC program in whose instruction part the

following information must be documented:

o Customer: Mubea

o System: Valve spring street 2

o Machine: Spring grinder

o Project no.: 4711

o Drawing number: 0815

o Main program: MP_Main

o Programmer: John Doe

o Created: 31.12.1900

o TwinCat version: V2.10 Build 1340

o Applied libraries: Regelungstechnik-toolbox.lib

o Last change: 1/1/2000 by John Doe

o IP addresses

o History:

For industrial data acquisition, each PLC control must provide signals in one status

doubleword (STATUS_PLC) . If for approved exceptions something other than a

Beckhoff PLC is used, then the signals for industrial data acquisition must still be

provided as digital output signals.

32


Table 13-1: Status messages PLC (communication PLC to Visu)

STATUS_PLC

bit/value Meaning

PLC

setting

PC set-

ting

PLC re-

set

PC re-

set Comment

00 / $0000 0001 Operational S R Set as soon as control voltage is

switched on

01 / $0000 0002 Malfunction message S R Set if at least 1 bit is set in the er-

ror array

02 / $0000 0004 Manual operation S R Manual operation switched on

03 / $0000 0008 Automatic mode running S R Automatic mode switched on

04 / $0000 0010 Automatic selected S R Set if automatic mode is stopped

or not started yet

05 / $0000 0020 Guard door open S R

06 / $0000 0040 Emergency stop S R At least 1 emergency stop actu-

ated

07 / $0000 0080 System available S R System available (for GEFF eval-

uation)

08 / $0000 0100 Operating mode selector switch in

setting "Off" S R

Operating mode selector switch in

neutral setting


setting "Manual" S R


setting "Manual"


setting "Automatic mode" S R


setting "Automatic mode"

11 / $0000 0800

12 / $0000 1000 Boot request S R

PLC requests new boot load: All

master data and parameters are

transmitted again

13 / $0000 2000 Teach master data S R Master data changed by PLC

14 / $0000 4000 Teach machine parameters S R Machine parameters changed by

PLC

15 / $0000 8000 SPC data S R SPC data or quantity change due

16 / $0001 0000

17 / $0002 0000

18 / $0004 0000

19 / $0008 0000

20 / $0010 0000

21 / $0020 0000

22 / $0040 0000

23 / $0080 0000

24 / $0100 0000

25 / $0200 0000

26 / $0400 0000

27 / $0800 0000

28 / $1000 0000

29 / $2000 0000

30 / $4000 0000

31 / $8000 0000 Watchdog S R Change status every 60 sec.

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If an overriding PC is used in the system then a second status doubleword

(STATUS_PC) transmits information on about the selected password level as well

as information on accepting changed master data and parameters.

Table 13-2: Responses from Visu (communication Visu to PLC)

STATUS_PC

bit/value Meaning

PLC

setting

PC set-

ting

PLC re-

set

PC re-

set Comment

00 / $0000 0001 Recipe change S R Recipe change by main computer

01 / $0000 0002 Master data changed S R Master data changed on main

computer

02 / $0000 0004 Machine parameters changed S R Machine parameters changed on

main computer

03 / $0000 0008

04 / $0000 0010 Password level S R

coded, 0..99








12 / $0000 1000

13 / $0000 2000

14 / $0000 4000

15 / $0000 8000

16 / $0001 0000

17 / $0002 0000

18 / $0004 0000

19 / $0008 0000

20 / $0010 0000

21 / $0020 0000

22 / $0040 0000

23 / $0080 0000

24 / $0100 0000

25 / $0200 0000

26 / $0400 0000

27 / $0800 0000

28 / $1000 0000

29 / $2000 0000

30 / $4000 0000

31 / $8000 0000 Watchdog PC S S Change status every 60 sec.

34


13.2 HMI design and programming

The HMI must be implemented with the software Galileo by Eaton or alternatively

with the software Delphi by Embarcadero Technologies.

A template for the operating masks and HMI design are shown in Figure 17-3,

Figure 17-5 and Figure 17-4 in the Appendix.

13.3 Symbols used

Bitmap library and Galileo sample project can be downloaded from the Mubea intranet

(see also table 17-1 Table 17-1 lines 4, 5):

Symbols in the status bar

Automatic

mode

selected

Automatic

mode

running

Manual opera-

tion

Basic setting

missing

Basic setting

o.k.

General

Caution

General fault

Emergency

stop

Guard door

Help

Operating mode selector switch

Left (off)

Neutral (manual opera-

tion)

Right (automatic mode)

End switch

End switch

assigned

End switch

free

End switch

occupied (basic

setting)

End switch

free (basic setting)

Button

Button on

Button off

35

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Buttons (also with different colours)

down

up

left

right

close

open

swivel

swivel

Button "browse"

Line down

Line up

Column left

Column right

Top

Bottom

EKS key status (operator level)

no key

Green

(worker)

Yellow

(fitter)

Black

(skilled worker)

Blue

(electronics engi-

neer)

Red

(programmer)

13.4 User interface design

Mask change with a touch on the machine element or on the rectangular, labeled

command button on the bottom or right monitor edge of the screen.

Deactivate operating elements for manual operation and label them as not operable

if the control is not in the “Manual” operating mode.

Display in the upper status bar in every mask:

o Icon for general fault in the left corner (flashing if there is a fault). A touch on

this icon triggers a jump to the error mask;

o the current operating mode (manual, auto selected, auto runs, auto stopped =

icon auto selected flashing);

o info icon in the right corner. A touch on icon triggers a jump to an overview with

the menu layout;

o the current operating level and if possible the operator name (of the EKS key).

Wherever possible, colour-code individual functional units as well as the associated

control buttons.

Display end switch in the system illustration and, if possible, additionally next to or

in the assigned control button.

Provide a help window with an explanation of the most important icons in the main

mask.

36


Show display and edition options of product-specific parameters (master data) and

system-specific (machine parameters) in separate masks. Secure the editing of pa-

rameters with operator key query or password. Machine parameters require a

higher operator level.

Position and condition of the safety systems must be visualized.

Colours:

o Background colour for masks: standard-grey

o Regular font colour: Black

o Entry fields with white background

Display on switch-on mask:

o Machine designation

o Circuit diagram number

o Project or stock number

o Creation date and contact information (e-mail: [email protected])

o Language switch

The text fields must be sufficiently dimensioned to leave a reserve of at least 30%

when filled with German text so that translated texts do not extend past the edge

of the text field.

13.5 Machine Data Acquisition (operating and process data)

Machine data can be collected for each system/system group and archived on a data

server in the Mubea network. This is the prerequisite for using the web-based PDC

cockpit, automatic e-mail protocols and data analysis with other tools. The data acqui-

sition is carried out by a tool, the so-called data collector, which reads data from the

plant control system and sends it to the data server.

The following requirements are given for data acquisition:

System control

o Standard interface OPC UA

OPC UA Server integrated in the controller.

If the controller does not contain an OPC UA server, a separate

OPC UA server must be installed on the service PC (additional li-

cense costs may arise).

Deviations from standard interface only after consultation.

o Definition of the required data with addresses (OPC item ID), descriptions

and acquisition criteria (see below).

37

ZBF-FA-6-002

Network configuration

o Integration into a separate VLAN (16/32/64/128/256 IP ranges) with routing

into the Mubea network, defined by IT.

o For non-Mubea systems with given incompatible IP addresses, a service PC

with two network adapters must be used as a gateway (see below).

Service-PC.

Depending on the circumstances, it may be necessary to use a service PC within

the VLAN.

o The data collector must be installed on a Windows-based computer, with

access to the system control and the Mubea network. The PC must have

sufficient free memory space for the offline buffer.

o If the OPC UA server is integrated in the plant control system, but the data

collector cannot be installed on it, the collector must be installed on a service

PC.

o If the system controller has a fixed incompatible IP address with Mubea net-

work, a second network adapter must be installed on the service PC. Thus,

the data collector can read machine data from the system control and send

it to the data server. At the same time, the service PC serves as a gateway

to the specific system network and can be used for remote access to the

controller (internally or by the system manufacturer).

o General system requirements for the service PC:

Basic configuration: Standard PC (Acer Veriton).

Observe protection class and environment.

At least 1 GB storage space for offline buffers.

Communication to the system control and central

database (install second network adapter if re-

quired).

Machine data to be collected are to be specified in tabular form when requesting a

proposal (see table "Machine data acquisition_Data Structures.xlsx").

38


39

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14 Capture of energy data

14.1 Procurement specification for measuring devices

The components for energy measurement (measuring devices and accessories)

are procured in coordination with the energy team in Attendorn (En team ATT).

Beforehand, the technical parameters of the system are clarified by the project de-

veloper and the technical parameters of the measurement technology are clarified

with the energy team in Attendorn ([email protected]). The contact persons

here are Ulrich Soest (German) and Tobias Hoffman (English), also for further que-

ries regarding the subject of measurement technology.

For each measuring point, a form is completed with the corresponding encoder-

parameters, which is submitted to KBR GmbH (www.kbr.de) together with the or-

der. KBR then parameterizes the measuring device directly and sends it to the cus-

tomer (internally at Mubea, but also to manufacturers of systems or control cabi-

nets). The customer provides the other accessories (motor circuit breaker, zero-

creator, current transducer, transducer terminals).

Should the systems not have an electrical zero point (4 conductor net), nor systems

for locations with 4 conductor nets (Mexico and USA), a zero creator is installed

into these systems, which creates a zero point for the supply of the measuring de-

vices.

Preferred types for energy measurement technology see:


14.2 Measurement of electric power

At a connector output between 10 and 50 kW, the “Beckhoff output measurement

clamp EL 3403-0010” is used (if a system is using Beckhoff control), otherwise, a

“MultiCount 3D6-1-LCD” is installed on the profile rail.

Starting with a power rating of 50 kW, an electricity meter of the type "MultiMess

4F144-1-LED-ESMS" must be installed in the control cabinet door.

The entire installation can also be seen in the following diagram.

http://www.kbr.de/

40


Figure 14-1: Decision criterion for the use of energy measurement technology.

Figure 14-2: Specification for energy measurement technology

In systems with several feeds > 10kW, for each input a measuring instrument is to

be designed in accordance with the above specifications, and interconnected ac-

cordinglyFigure 14-3.

Figure 14-3: Electricity meter installation

41

ZBF-FA-6-002

The connections of the current transducers used must be guided out on terminals

with which they can be short circuited.

The connections of the eBus are also directed downwards on the control cabinet,

where the individual system parts can be connected with each other.

Each system/production line receives an interface converter “MultySys3D2-ESET”

from the Ethernet to the serial energy bus (see list of feed preferences); 3-wire-bus

with A, B, ground and in addition, the shield. The energy-bus structure (eBus) must

be line shaped (no star or tree structure); a terminating resistor of 120

must be installed on the last bus member; for this purpose, J-Y(ST)Y EIB

cable is to be used (see list of feed preferences) and the shield is always

to be applied only on one side. The connection with the Mubea network must be

established with the manageable system switch (see list of feed preferences).

14.3 Measurement of other media

All meters (gas, compressed air, water) must be electronic and have a "potential-

free contact" (no meters with M-BUS or Mod-Bus function) that is connected to an

input on a “MultiSio D6-ESBSDS-5DI6RO1DO-6“device. For this purpose, there

are extension modules for digital and analogue inputs (see list of feed preferences).

The preferred types for electronic pulse counters (gas, compressed air, water,

wastewater) differ depending on pipe diameter and required max. hourly flow rate.

Figure 14-3: Measuring section at the installation of meters

Please note during meter installation: There must be a straight pipe piece with at

least 5 x d as a stabilization section before and after the meter (d = pipe diameter).

The meter must be shut off with valves on both sides and the supply secured by a

bypass for repair and cleaning purposes (if the system cannot be switched off). The

bypass is normally blocked with a valve.

A filter must be provided for meters.

42


14.4 Gases / compressed air

Always measure natural gas.

Departments or large systems should be measured separately in the area of gases

/ compressed air.

A filter must be provided for gas meters.

It must additionally be ensured that only one main gas or compressed air supply

line is laid per system (especially with production lines) and that the meters are

installed in that line. If these gas / compressed air stubs are not required (ring lines

because of higher supply safety), an optional supply line for the production line can

be laid in parallel to the main. The gas / compressed air meter must be installed in

this parallel line and the line must be lockable with valves on both sides. The me-

dium normally always flows through the meter and the other side of the duct is

blocked.

Figure 14-4: Illustration of the overall system

A temporary consumption measurement should generally be carried out for all fu-

ture new systems during commissioning – especially smaller individual systems. If

compressed air is used, the consumption per 1,000 parts must be measured (with

different consumption levels based on different products, a mean value should be

calculated). These consumption values should be managed together with the ap-

propriate cost point numbers.

43

ZBF-FA-6-002

14.5 Measurement of water

A water flow meter (separated according to municipal water and any well water)

must be installed with the water supply.

With cooling systems and evaporative coolers, a water meter must also be installed

because the evaporated water volumes must also be specified.

With systems that feed wastewater into the drainage system, an additional volume

meter must be installed for the wastewater.

44


15 Miscellaneous

15.1 Linking of systems

If two or more individual machines are linked in one overall system, then the hard-

ware of the emergency stop buttons of each individual machine must be led to the

outside with 2 ducts in order to be able to set one overall emergency stop circuit.

45

ZBF-FA-6-002

16 Lists of preferred parts and preferred configura-

tions

Preferred parts are either to me designated as individual components with identifica-

tion/article number or alternatively as component lines or a series or a manufacturer.

The list of preferred parts and the overview of the preferred configurations are attached

as an individual document.

46


17 Appendix

17.1 Linked documents and links

Linked documents are stored on the internal Mubea Intranet (www.mubea-net.de) un-

der "Central units" > "Tool making" > "Control technology" > "Functional specification".

Table 17-1: Cross references to documents and links

No. Document Document name

1 Profibus measurement Profibus_Messung.pdf

2 Profibus document Profibus-Doku.pdf

3 Bitmap library visu_images_neu.zip

4 Galileo sample project Galileo_Beispiel.zip

5 Test report DGUV DGUV V3 Formblatt Prüfung elektr..xls

6 List of preferred parts Mubea_Pflichtenheft_Teil_2_Preferred_electronic_compo-nents.xlsx

7 Definition OEE Mubea OEE_Verluste_V08_deu+engl.pdf

8 Definition of machine data Machine data acquisition_Data Structures.xlsx

17.2 Figures

Figure 17-1: Screenshot of the ASi monitor protocol (incl. version no.)

http://www.mubea-net.de/

47

ZBF-FA-6-002

Figure 17-2: Proximity switch – preferred sensor types Festo

Figure 17-3: Main mask (left) and operation mask manual functions (right)

Figure 17-4: Masks with orders (left) and recipes (right)

Figure 17-5: Mask error log (left) and system information (right)

48


Figure 17-6: Rittal Optipanel type 9328009, hole pattern with button and 7" touch panel

mubea specification - part 1 · a1 – control cabinet – location designation +01 o functional...

Documents